CN109622909B - Forming method of high solid-phase semi-solid damping tower - Google Patents
Forming method of high solid-phase semi-solid damping tower Download PDFInfo
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
- B22D17/00—Pressure die casting or injection die casting, i.e. casting in which the metal is forced into a mould under high pressure
- B22D17/007—Semi-solid pressure die casting
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
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Abstract
The invention discloses a molding method of a high solid-phase semi-solid damping tower, which is based on an SEED high solid-phase pulping unit and an EMS electromagnetic stirring unit or a GISS electromagnetic stirring unit and comprises the following steps: aluminum liquid pouring, namely feeding the aluminum liquid for pulping into an SEED high solid phase pulping unit for aluminum liquid pouring; preparing slurry, namely preparing the aluminum liquid into high solid-phase semi-solid slurry in an SEED high solid-phase pulping unit; transferring the slurry, namely transferring the prepared slurry into a material pipe arranged on a mould; and (4) die-casting and forming, namely starting a punch for a die-casting machine to die-cast the slurry into a damping tower workpiece. The molding method changes the raw materials, reduces the quality of parts and is beneficial to the light weight of the automobile; compared with the traditional technology, the structure state of the raw materials is changed through the pulping process, the pouring temperature is close to the solidus temperature, the filling speed is stable, the air entrainment probability in the filling process is reduced, the density of the product is increased, and the mechanical property of the cast product can be met; the die-casting cost of the shock absorption tower is saved.
Description
Technical Field
The invention relates to the technical field of shock absorber forming, in particular to a forming method of a high solid-phase semi-solid shock absorber.
Background
At present, common vehicle types of damping towers are welded by steel plates; the luxury vehicle is formed by a high-vacuum aluminum alloy die-casting process.
The first method, steel plate welding, is not suitable for the trend of light weight development of automobiles due to the large specific gravity of the materials.
The second method is a high vacuum aluminum alloy die-casting process, and the process route is as follows: material smelting → high pressure die casting + high vacuum → T6 heat treatment; the elongation rate of the product in an as-cast state hardly reaches 10 percent, heat treatment is needed, the cost is high and is about 120 yuan/kg; the air content of the shock absorption tower is controlled within 0.5cc/100g, which has strict requirements on high vacuum degree in the whole filling process (the vacuum degree is below 50 mbar), and the method is not easy to realize stably under the challenging die casting production environment. Like this kind of large-scale and complicated die casting of shape, to guarantee that the die cavity can reach high vacuum state, the blind hole position can only be filled up and the foundry goods gas content is reduced to the aluminium material, therefore the mould needs to use efficient vacuum valve (big bleed area). The general high-efficiency vacuum mechanical valve has a plurality of moving parts, and can ensure smooth production only by frequent maintenance and cleaning, so that the use is inconvenient; besides good sealing performance of a die, a pressure chamber, an integral punch system (comprising a punch, a material pipe, lubrication and a spreader cone), and the like, special high-vacuum equipment is required to ensure the stability of the injection speed and the minimum gas generation amount.
Disclosure of Invention
The invention aims to provide a method for molding a high solid-phase semi-solid damping tower, which solves the technical problems of complex process, high cost and poor product quality of the existing molding method.
In order to achieve the purpose, the technical scheme provided by the invention is as follows:
in a first aspect, the invention provides a method for molding a high solid-phase semi-solid damping tower, which is based on an SEED high solid-phase pulping unit and an EMS electromagnetic stirring unit, and comprises the following steps:
firstly, aluminum liquid pouring, namely feeding aluminum liquid for pulping into an SEED high solid phase pulping unit for aluminum liquid pouring;
secondly, preparing slurry, namely preparing the aluminum liquid into high solid-phase semi-solid slurry in an SEED high solid-phase pulping unit;
thirdly, transferring the slurry, namely transferring the prepared slurry into a material pipe arranged on a mould;
and fourthly, die-casting and forming, wherein a punch for a die-casting machine is started to die-cast the slurry into a damping tower workpiece.
Wherein the second step of slurry preparation comprises the following steps:
step A1, pouring aluminum liquid into a crucible cylinder of the SEED high solid phase pulping unit;
a2, moving and surrounding a stirring device of the EMS electromagnetic stirring unit to the outside of the crucible cylinder;
and step A3, synchronously starting the SEED high solid phase pulping unit and the EMS electromagnetic stirring unit, and electromagnetically stirring the crucible cylinder to pulp while rotating in the horizontal plane.
The step A1 of pouring the aluminum liquid into the crucible cylinder of the SEED high solid phase pulping unit comprises the following steps:
step A11, pouring aluminum liquid by inclining the crucible barrel by 45 degrees;
and step A12, erecting the crucible cylinder and shaking up the aluminum liquid.
In the step of moving and surrounding the stirring device of the EMS electromagnetic stirring unit to the outside of the crucible cylinder in the step a2, the EMS electromagnetic stirring unit only acts on the aluminum liquid at a position above the middle part of the crucible cylinder.
And step A3, synchronously starting the SEED high solid phase pulping unit and the EMS electromagnetic stirring unit, wherein in the step of pulping, the crucible cylinder rotates in the horizontal plane and is electromagnetically stirred at the same time of rotating in the horizontal plane, and the crucible cylinder rotates in the horizontal plane and eccentrically rotates relative to a stirring device of the EMS electromagnetic stirring unit.
And step A3, synchronously starting the SEED high solid phase pulping unit and the EMS electromagnetic stirring unit, and keeping the outer wall of the crucible cylinder and the inner wall of the electromagnetic stirring device of the EMS electromagnetic stirring unit in a separation state in the step of performing pulping by electromagnetically stirring while the crucible cylinder rotates in the horizontal plane.
Wherein, the distance scope between the outer wall of a crucible section of thick bamboo and the inner wall of EMS electromagnetic stirring unit's agitating unit is: 30-40 mm.
In a second aspect, the method for forming the high solid-phase and semi-solid-phase damping tower is based on a SEED high solid-phase pulping unit and a GISS low solid-phase pulping unit, and comprises the following steps:
step one, pouring aluminum liquid, namely feeding the aluminum liquid for pulping into a crucible of an SEED high solid phase pulping unit;
step two, preparing slurry, namely preparing the aluminum liquid into high solid-phase semi-solid slurry in an SEED high solid-phase pulping unit;
transferring the slurry, namely transferring the prepared slurry into a material pipe arranged on a mould;
and step four, die-casting and forming, wherein a punch for a die-casting machine is started to die-cast the slurry into a damping tower workpiece.
Wherein, the preparation of the slurry in the second step comprises the following steps:
b1, starting the SEED high solid phase pulping unit to start pulping;
step B2, starting the GISS low solid phase pulping unit at the initial stage of pulping by the SEED high solid phase pulping unit, and inserting the graphite tube of the GISS low solid phase pulping unit into the SEED crucible;
step B3, stopping the GISS low solid phase pulping unit when the temperature of the overheated aluminum liquid for pulping begins to fall into the range of the semi-solid state interval;
and step B4, keeping the crucible of the SEED high solid phase pulping unit rotated and shaken until the slurry reaches the required solid phase rate, and finishing pulping.
In the step B2, in the initial pulping stage of the SEED high solid phase pulping unit, the GISS low solid phase pulping unit is started, and the graphite tube of the GISS low solid phase pulping unit is inserted into the SEED crucible, wherein in the initial pulping stage, the molten aluminum is above the temperature of the superheated liquid phase, and the temperature range of the superheated liquid phase is as follows: 620 ℃ and 640 ℃.
And B2, starting the GISS low solid phase pulping unit at the initial stage of pulping by the SEED high solid phase pulping unit, inserting a graphite pipe of the GISS low solid phase pulping unit into the SEED crucible, synchronously rotating the graphite pipe and the SEED crucible after the graphite pipe is inserted into the SEED crucible, and simultaneously blowing nitrogen to catalyze pulping.
Wherein, the parameter range of the temperature of the overheated aluminum liquid falling into the semi-solid range in the step B3 when the temperature of the overheated aluminum liquid starts falling into the semi-solid range in the step of stopping the GISS low solid phase pulping unit is as follows: the temperature of the aluminum liquid is 590-620 ℃, and the solid phase rate is 10-15%.
And B3, stopping the GISS low solid phase pulping unit when the temperature of the overheated aluminum liquid begins to fall into the range of the semi-solid state interval in the pulping step, wherein the fluidity of the aluminum liquid needs to be maintained in the step of stopping the GISS low solid phase pulping unit.
In the step B3, when the temperature of the overheated aluminum liquid for pulping starts to fall into the range of the semi-solid range, the GISS low-solid phase pulping unit is stopped in the step of stopping the GISS low-solid phase pulping unit, specifically, nitrogen is stopped from being blown in, and the graphite pipe is lifted out of the crucible from the crucible of the SEED high-solid phase pulping unit.
Step B4, the crucible of the SEED high solid phase pulping unit is kept to rotate and shake until the slurry reaches the required solid phase rate, and in the step of finishing pulping, the solid phase rate ranges are as follows: 40-60 percent.
Compared with the prior art, the forming method of the high solid-phase semi-solid damping tower changes the raw materials, reduces the quality of parts and is beneficial to the light weight of automobiles; the main differences compared with the conventional technology two are: the structure state of the raw materials is changed by the pulping process, the pouring temperature is close to the solidus temperature, the filling speed is stable, the air entrainment probability in the filling process is reduced, the density of the product is increased, and the mechanical property of the cast product (without heat treatment) can be met; the die-casting cost of the shock absorption tower is saved.
Drawings
Fig. 1 is a main flow chart of a method for forming a high solid-phase semi-solid shock-absorbing tower according to the present invention.
Detailed Description
The invention will be further elucidated with reference to the drawing.
Referring to fig. 1, in the present embodiment, the method for forming a high solid-phase semi-solid damping tower is based on an SEED high solid-phase pulping unit and an EMS electromagnetic stirring unit, and includes the following steps:
step S1, aluminum liquid pouring, wherein the aluminum liquid for pulping is sent to an SEED high solid phase pulping unit for aluminum liquid pouring;
s2, preparing slurry, namely preparing the aluminum liquid into high solid-phase semi-solid slurry in an SEED high solid-phase pulping unit;
step S3, slurry transfer, namely transferring the prepared slurry into a material pipe arranged on a mould;
and step S4, die-casting, wherein a punch head for a die-casting machine is started to die-cast the slurry into the damping tower workpiece.
Wherein the step of preparing the slurry of the second step S2 comprises:
step A1, pouring aluminum liquid into a crucible cylinder of the SEED high solid phase pulping unit;
a2, moving and surrounding a stirring device of the EMS electromagnetic stirring unit to the outside of the crucible cylinder;
and step A3, synchronously starting the SEED high solid phase pulping unit and the EMS electromagnetic stirring unit, and electromagnetically stirring the crucible cylinder to pulp while rotating in the horizontal plane.
Wherein, the step of pouring the aluminum liquid into the crucible cylinder of the SEED high solid phase pulping unit in the step A1 comprises the following steps:
step A11, pouring aluminum liquid by inclining the crucible barrel by 45 degrees;
and step A12, erecting the crucible cylinder and shaking up the aluminum liquid.
In the step of moving and surrounding the stirring device of the EMS electromagnetic stirring unit to the outside of the crucible cylinder in the step A2, the EMS electromagnetic stirring unit only acts on the aluminum liquid at the position above the middle part of the crucible cylinder.
And step A3, synchronously starting the SEED high solid phase pulping unit and the EMS electromagnetic stirring unit, wherein in the step of pulping, the crucible cylinder rotates in the horizontal plane and is electromagnetically stirred at the same time of rotating in the horizontal plane, and the crucible cylinder rotates in the horizontal plane and eccentrically rotates relative to a stirring device of the EMS electromagnetic stirring unit.
And step A3, synchronously starting the SEED high solid phase pulping unit and the EMS electromagnetic stirring unit, and keeping the outer wall of the crucible cylinder and the inner wall of the electromagnetic stirring device of the EMS electromagnetic stirring unit in a separation state in the step of performing pulping by electromagnetically stirring while the crucible cylinder rotates in the horizontal plane.
Wherein, the distance scope between the outer wall of a crucible section of thick bamboo and the inner wall of EMS electromagnetic stirring unit's agitating unit is: 30-40 mm.
In the process of SEED operation, because upright crucible section of thick bamboo structure is that the little lower part diameter of upper portion diameter is big (make into big end down and make things convenient for thick liquids to discharge to the plenum chamber, this kind of structure has a drawing of patterns inclination in being equivalent to the crucible section of thick bamboo), and the upper portion aluminium liquid's in the section of thick bamboo mass distribution just is littleer than the lower part, upper portion is with air direct contact simultaneously, these two aspects lead to the actual radiating rate of upper portion slightly to be faster than well lower part, when so along with the temperature changes from overheated liquid to semi-solid state temperature interval, the mode of electromagnetic stirring is adopted simultaneously to the aluminium liquid of well upper portion, can make the solid fraction of the thick liquids of well upper portion more even unanimous, simultaneously because the characteristic of electromagnetic stirring makes the.
In this embodiment, in the process of SEED operation, electromagnetic stirring equipment is used simultaneously in the shaking pulping process for the slurry at the middle upper part of the crucible barrel, namely, two methods are used simultaneously to prepare the semi-solid slurry. After the pouring of SEED crucible section of thick bamboo goes into aluminium liquid, shift into to rock the position perpendicularly after from 45 degrees angle pouring positions, electromagnetic stirring device from the top and descend, crucible section of thick bamboo is located cylindrical electromagnetic stirring work effect's space, SEED crucible section of thick bamboo is opened at the horizontal plane internal rotation, open electromagnetic stirring device's magnetic field (electromagnetic stirring device motionless) SEED crucible section of thick bamboo simultaneously and present the motion of doing eccentric rotation around its axis in its inside cylindrical space, the outer wall of SEED crucible section of thick bamboo and the inner wall of cylindrical work interval contactless in the electromagnetic stirring device, keep 30 ~ 40 millimeter space. After the pulping is finished, the frequency converter of the electromagnetic stirring device is closed, the whole electromagnetic stirring device is lifted, the SEED crucible cylinder is rotated to a conveying position from a rotary shaking position, and the pulping is finished to prepare for discharging at a discharging position of a die casting machine.
Compared with the prior art, the forming method of the high solid-phase semi-solid damping tower adopts the SEED + EMS composite pulping process, so that the uniformity of the solid fraction and the consistency of the grain size of the slurry prepared by the SEED process are improved, the quality of the slurry is improved, and the quality of the high solid-phase semi-solid casting is improved.
In another second embodiment of the method for forming a high solid-phase semi-solid damping tower, which is based on SEED high solid-phase pulping unit and GISS low solid-phase pulping unit, the following cast aluminum 357 is taken as an example, and comprises the following steps:
step S10, aluminum liquid pouring, wherein the aluminum liquid for pulping is sent to an SEED high solid phase pulping unit for aluminum liquid pouring;
step two, S20, preparing slurry, namely preparing the aluminum liquid into high solid phase semi-solid slurry in an SEED high solid phase pulping unit;
step three, S30, transferring the slurry, namely transferring the prepared slurry into a material pipe arranged on the die;
and step S40, die-casting, wherein a punch for a die-casting machine is started to die-cast the slurry into the damping tower workpiece.
Wherein the second step S20 slurry preparation comprises the following steps:
b1, starting the SEED high solid phase pulping unit to start pulping;
step B2, starting the GISS low solid phase pulping unit at the initial stage of pulping by the SEED high solid phase pulping unit, and inserting the graphite tube of the GISS low solid phase pulping unit into the SEED crucible;
step B3, stopping the GISS low solid phase pulping unit when the temperature of the overheated aluminum liquid for pulping begins to fall into the range of the semi-solid state interval;
and step B4, keeping the crucible of the SEED high solid phase pulping unit rotated and shaken until the slurry reaches the required solid phase rate, and finishing pulping.
In the step B2, in the initial pulping stage of the SEED high solid phase pulping unit, the GISS low solid phase pulping unit is started, and the graphite tube of the GISS low solid phase pulping unit is inserted into the SEED crucible, wherein in the initial pulping stage, the molten aluminum is above the temperature of the superheated liquid phase, and the temperature range of the superheated liquid phase is as follows: 620 ℃ and 640 ℃.
And B2, starting the GISS low solid phase pulping unit at the initial stage of pulping by the SEED high solid phase pulping unit, inserting a graphite pipe of the GISS low solid phase pulping unit into the SEED crucible, synchronously rotating the graphite pipe and the SEED crucible after the graphite pipe is inserted into the SEED crucible, and simultaneously blowing nitrogen to catalyze pulping.
Wherein, the parameter range of the temperature of the overheated aluminum liquid falling into the semi-solid range in the step B3 when the temperature of the overheated aluminum liquid starts falling into the semi-solid range in the step of stopping the GISS low solid phase pulping unit is as follows: the pulping time is 2-10 seconds, the temperature of the aluminum liquid is 590-620 ℃, and the solid phase rate is 10-15%.
In the step B3, when the temperature of the overheated aluminum liquid for pulping starts to fall into the range of the semi-solid state interval, the flowability and the proper low solid state of the aluminum liquid need to be maintained in the step of stopping the GISS low solid phase pulping unit.
And B3, stopping the GISS low solid phase pulping unit in the step of stopping the GISS low solid phase pulping unit, namely stopping the nitrogen injection and lifting the graphite pipe from the crucible of the SEED high solid phase pulping unit.
Step B4, the crucible of the SEED high solid phase pulping unit is kept to rotate and shake until the slurry reaches the required solid phase rate, and in the step of finishing pulping, the solid phase rate ranges are as follows: 40-60 percent.
In other embodiments, the liquidus and semi-solid temperature ranges are different due to different types of specific alloys, and need to be adjusted according to actual conditions.
In the working process of the SEED high solid phase pulping unit, the temperature of the overheated aluminum liquid is gradually reduced to a semi-solid state interval because the overheated slurry is naturally cooled, the time of the whole process is longer, and the GISS composite pulping method is used, so that the overheated aluminum liquid can be quickly cooled at the initial stage and more primary alpha phases are generated, and the efficiency and the quality of preparing the slurry are improved.
Compared with the prior art, the method for forming the high solid-phase semi-solid damping tower in the second embodiment combines the advantages of the two independent semi-solid pulping modes at present, and the two processes are overlapped to form a front and back composite pulping process in the same time period, so that the efficiency of preparing the slurry by the SEED single method is improved, particularly, when large-size (more than ten kilograms) slurry is prepared, the problem of uneven solid phase rate distribution in the slurry preparation process can be solved, and the efficiency of high solid-phase semi-solid die casting is improved.
In conclusion, the raw materials are changed, the quality of parts is reduced, and the light weight of the automobile is facilitated; the main differences compared with the conventional technology two are: the structure state of the raw materials is changed by the pulping process, the pouring temperature is close to the solidus temperature, the filling speed is stable, the air entrainment probability in the filling process is reduced, the density of the product is increased, and the mechanical property of the cast product (without heat treatment) can be met; according to the calculation, the price of the aluminum alloy automobile damping tower formed by the original high-vacuum die-casting process is 180 yuan/Kg, the price of the aluminum alloy damping tower formed by the high-solid-phase-rate semi-solid process is about 60-70 yuan/Kg, and the reduction of each kilogram exceeds 50%.
The above-mentioned embodiments are merely preferred examples of the present invention, and not intended to limit the present invention, and those skilled in the art can easily make various changes and modifications according to the main concept and spirit of the present invention, so that the protection scope of the present invention shall be subject to the protection scope of the claims.
Claims (1)
1. A molding method of a high solid-phase semi-solid damping tower is based on an SEED high solid-phase pulping unit and an EMS electromagnetic stirring unit, and comprises the following steps:
firstly, aluminum liquid pouring, namely feeding aluminum liquid for pulping into an SEED high solid phase pulping unit for aluminum liquid pouring;
secondly, preparing slurry, namely preparing the aluminum liquid into high solid-phase semi-solid slurry in an SEED high solid-phase pulping unit;
thirdly, transferring the slurry, namely transferring the prepared slurry into a material pipe arranged on a mould;
fourthly, die-casting and forming, namely starting a punch for a die-casting machine to die-cast the slurry into a damping tower workpiece; the second step S2 of preparing the slurry includes:
step A1, pouring aluminum liquid into a crucible cylinder of the SEED high solid phase pulping unit;
a2, moving and surrounding a stirring device of the EMS electromagnetic stirring unit to the outside of the crucible cylinder;
step A3, synchronously starting the SEED high solid phase pulping unit and the EMS electromagnetic stirring unit, wherein the crucible cylinder rotates in the horizontal plane and is electromagnetically stirred to pulp, and the step A1 of pouring aluminum liquid into the crucible cylinder of the SEED high solid phase pulping unit comprises the following steps:
step A11, pouring aluminum liquid by inclining the crucible barrel by 45 degrees;
step A12, erecting the crucible cylinder and shaking up the aluminum liquid;
in the step of moving and surrounding the stirring device of the EMS electromagnetic stirring unit to the outside of the crucible barrel in the step a2, the EMS electromagnetic stirring unit only acts on the aluminum liquid at a position above the middle of the crucible barrel, the step A3 synchronously starts the SEED high solid phase pulping unit and the EMS electromagnetic stirring unit, and in the step of electromagnetically stirring the crucible barrel while rotating in the horizontal plane to prepare the pulp, the crucible barrel rotates in the horizontal plane and eccentrically rotates relative to the stirring device of the EMS electromagnetic stirring unit.
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| US6428636B2 (en) * | 1999-07-26 | 2002-08-06 | Alcan International, Ltd. | Semi-solid concentration processing of metallic alloys |
| CN1994622A (en) * | 2006-11-24 | 2007-07-11 | 清华大学 | Slurrying-forming separated aluminium alloy rheological forming method |
| EP2535126B1 (en) * | 2011-06-16 | 2017-04-05 | Cie Automotive, S.A. | Device and method for obtaining semi-solid sludges |
| CN106413940B (en) * | 2014-05-16 | 2020-08-25 | 吉斯科有限公司 | Method for producing molten metal for casting at low to zero superheat temperatures |
| CN105583385B (en) * | 2015-05-20 | 2017-12-12 | 江苏凯特汽车部件有限公司 | A kind of device for continuously fast preparing of aluminum alloy wheel of vehicle semi solid slurry |
| CN108746540A (en) * | 2018-06-20 | 2018-11-06 | 福建省杰豪半固态泵压科技有限责任公司 | A kind of electromagnetic system prepares semi-solid forming method |
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Address after: Building 102, No. 5, No. 19 Huanguan South Road, Junjunbu Community, Guanlan Street, Longhua District, Shenzhen City, Guangdong Province, 518000 Patentee after: Aikodi (Shenzhen) Precision Parts Co.,Ltd. Address before: 518000 1-2 / F, building B, hongyufa Industrial Park, 19 huanguan South Road, Junlong community, Guanlan street, Longhua New District, Shenzhen City, Guangdong Province Patentee before: SHENZHEN SILVER BASIS DIE CASTING TECHNOLOGY CO.,LTD. |